Disposable absorbent articles

ABSTRACT

An absorbent article comprising first and second belts. The article may comprise a center chassis that comprises barrier leg cuffs extending laterally outward of a backsheet in the crotch region.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims priority under 35U.S.C. § 120 to, U.S. patent application Ser. No. 14/206,034, filed onMar. 12, 2014, which claims the benefit, under 35 USC § 119(e), of U.S.Provisional Patent Application Serial No. 61/804,276, filed on Mar. 22,2013, the entire disclosures of which are fully incorporated byreference herein.

FIELD OF THE INVENTION

The present invention relates to disposable absorbent articlescomprising shaped belts.

BACKGROUND OF THE INVENTION

Many adult incontinence products comprise elastic strands as the stretchengine in the waist region, where the strands are laminated between asingle outer cover nonwoven and two discrete inner nonwoven belts. Whilemost of the strands are parallel and run in the lateral direction in thewaist regions of these products. Curved elastics often follow the legcutout in the crotch region and the waist regions adjacent to the crotchregion. Curving the elastics, however can be complicated and can slowthe production of these products. Applicants disclose a design belowthat provides a full outer cover nonwoven without the need to includecurved elastics. In fact, Applicants provide for straight elastics thatextend into the crotch from both the front and rear waist regions, thusproviding for articles that are simpler to make and that provide forincreased coverage (especially in the rear) and that fit a broad rangeof consumers.

Applicants have also disclosed the combination of leg cutouts thatprovide for improved fit and coverage in combination with Applicants'disclosed elastic profile. And, further, Applicants have disclosedembodiments that may add leg cuffs to the center chassis to furtherimprove protection against leaks.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as formingthe present invention, it is believed that the invention will be betterunderstood from the following description which is taken in conjunctionwith the accompanying drawings in which like designations are used todesignate substantially identical elements, and in which:

FIG. 1 is a perspective view of an exemplary disposable pull-on garmentin a typical in-use configuration;

FIG. 2 is a perspective view of an exemplary disposable pull-on garmentin a typical in-use configuration;

FIG. 3 is a plan view of the pull-on garment in its flat uncontractedcondition showing the inner surface;

FIG. 4A is a schematic cross section view of a first embodiment takenalong line 4-4 in FIG. 3 of an exemplary disposable pull-on garment;

FIG. 4B is a schematic cross section view of a second embodiment takenalong line 4-4 in FIG. 3 of an exemplary disposable pull-on garment;

FIG. 4C is a schematic cross section view of a third embodiment takenalong line 4-4 in FIG. 3 of an exemplary disposable pull-on garment;

FIG. 4D is a schematic cross section view of a fourth embodiment takenalong line 4-4 in

FIG. 3 of an exemplary disposable pull-on garment;

FIG. 4E is a schematic cross section view of a sixth embodiment takenalong line 4-4 in FIG. 3 of an exemplary disposable pull-on garment;

FIG. 4F is a schematic cross section view of a seventh embodiment takenalong line 4-4 in FIG. 3 of an exemplary disposable pull-on garment;

FIG. 4G is a schematic cross section view of an eight embodiment takenalong line 4-4 in FIG. 3 of an exemplary disposable pull-on garment;

FIG. 5A is a schematic cross section view taken along line 5-5 in FIG. 3of an example of a folded outer leg cuff suitable in one embodiment ofthe invention;

FIG. 5B is a schematic cross section view taken along line 5-5 in FIG. 3of an alternative embodiment example of a folded leg cuff suitable inone embodiment of the invention;

FIG. 6 is a plan view of the pull-on garment of FIG. 4D in its flatuncontracted condition showing the inner surface.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the term “pull-on garment” refers to articles of wearwhich have a defined waist opening and a pair of leg openings and whichare pulled onto the body of the wearer by inserting the legs into theleg openings and pulling the article up over the waist. The term“disposable” is used herein to describe garments which are not intendedto be laundered or otherwise restored or reused as a garment (i.e., theyare intended to be discarded after a single use and to be recycled,composted or otherwise disposed of in an environmentally compatiblemanner). The pull-on garment may be “absorbent” such that it absorbs andcontains the various exudates discharged from the body.

As used herein, the term “absorbent article” refers to pull-on garmentsgenerally worn by infants and other incontinent individuals to absorband contain urine, feces and/or menses. It should be understood,however, that the term absorbent article is also applicable to othergarments such as training pants, incontinent briefs, feminine hygienegarments or panties, and the like.

As used herein, the terms “elastic,” “elastomer,” and “elastomeric”refer to a material which generally is able to extend to a strain of atleast 50% without breaking or rupturing, and is able to recoversubstantially to its original dimensions, accounting for set, after thedeforming force has been removed.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

FIG. 1 is a perspective view of the absorbent article 20. FIG. 2 is aperspective view of the absorbent article 20. The absorbent article 20has a longitudinal centerline L1 and a transverse centerline T1 (referto FIG. 3 as well). The absorbent article 20 has an outer surface 22, aninner surface 24 opposed to the outer surface 22, a front region 26, aback region 28, a crotch region 30, and seams 32 which join the frontregion 26 and the back region 28 to form two leg openings 34 and a waistopening 36. Also referring to FIGS. 1-3, the absorbent article 20comprises a main portion 1, a side portion 2, and a waist portion 3.

In the embodiment shown in FIGS. 1 and 3, the absorbent article 20comprises an absorbent main body 38 (hereinafter may be referred to as“main body” or “central chassis”) to cover the crotch region of thewearer and a belt 40 extending transversely about the waist opening 36.The absorbent article 20 may also comprise an outer cover layer 42 tocover the main body 38. The belt 40 defines the waist opening 36. Thebelt 40, the main body 38 and/or the outer cover layer 42 jointly definethe leg opening 34. As shown in FIG. 3 and FIG. 6, the portions of thebelts making up leg openings 34 may be shaped. In the FIG. 3 embodiment,the front belt 84 may be concave and the rear belt may have a convexportion. Alternatively, both the front and rear belts may be concave orboth may be convex. Also alternatively, the front belt may be convex andthe rear belt may be concave. While FIG. 3 illustrates discrete firstbelt layers 83, FIG. 6 illustrates a full outer cover nonwoven firstbelt layer 82. In FIG. 6, the leg cutout also cuts through the secondbelt layers 83 a and b.

In the embodiment shown in FIG. 2 the absorbent article 20 comprises anabsorbent main body 38 to cover the crotch region of the wearer and abelt 40 extending transversely about the waist opening 36. The absorbentarticle 20 may also comprise an outer cover layer 42 to cover the mainbody 38. The belt 40 defines the waist opening 36. The belt 40, the mainbody 38 and/or the outer cover layer 42 jointly define the leg opening34. One or more of the belt layers may extend from a first waist edge134 in a first waist region 26 through the crotch region to alongitudinally opposing second waist edge 138 in a second waist region28 and may form a portion or the whole of the outer surface of theabsorbent article 20.

The absorbent main body 38 absorbs and contains body exudates disposedon the main body 38. In the embodiment shown in FIG. 3, the main body 38has a generally rectangular shape having a longitudinal centerline L1, atransverse centerline T1, left and right longitudinally extending sideedges 48 (hereinafter may be referred to as “longitudinal side edge”)and front and back transversely extending end edges 50 (hereinafter maybe referred to as “transverse end edge”). The main body 38 also haswaist panels (i.e., a front waist panel 52 positioned in the front waistregion 26 of the absorbent article 20 and a back waist panel 54positioned in the back waist region 28) and a crotch panel 56 in thecrotch region 30 between the front and back waist panels 52, 54.

In the embodiment shown in FIG. 4A and 4B, the absorbent articles 20 maycomprise front and rear belts 84, 86 intended to encircle at least aportion of the waist of the wearer, the front and rear belt portions 84,86 being connected by a main body 38 forming the crotch region 30 of theabsorbent article 20. The front and rear belts 84 and 86 may be formedfrom a first belt layer forming a portion of the outer surface 22 of theabsorbent article, the first belt layer 82 may be formed of twolongitudinally spaced webs of material. The front and rear belts 84 and86 may also comprise a second belt layer 83 forming a portion of theinner surface 24 of the absorbent article 20, the second belt layer 83may also be formed of two longitudinally spaced webs of material. Thesecond belt layer may also be discontinuous and spaced apart in atransverse direction. The first and second belt layers 82, 83 may beformed of substantially the same material or may comprise differentmaterials. The first and second belt layers 82, 83 may be formed fromnonwovens, films, foams, elastic nonwoven, or combinations thereof. Thefront and rear belts 84, 86 may also comprise an elastomeric materialdisposed between the first and second belt layers 82, 83. Theelastomeric material may comprise one or more elastic strands,elastomeric films, elastomeric ribbons, elastomeric nonwovens,elastomeric filaments, elastomeric adhesives, elastomeric foams, scrimsor combinations thereof. A portion of the elastomeric material may bedirectly combined with the outer cover layer. The main body 38 (alsoreferred to as a central chassis) of the absorbent article may comprisean outer surface 22, backsheet 60, an inner surface 24, topsheet 58, andan absorbent core 62 disposed between the topsheet 58 and the backsheet60. The backsheet may be formed of a nonwoven material, woven material,films or laminates comprising a combination of one or more of thesematerials. In one embodiment the backsheet is a film and nonwovenlaminate wherein the nonwoven of the laminate is the outer cover layer.In addition, the main body 38 may comprise elasticized barrier leg cuffs64 disposed at or adjacent the side edges of the main body. The frontand rear belts 84, 86 may overlap at least a portion of the main bodyand one or both of the belt portions may be disposed on the outersurface of the main body or alternatively on the inner surface of themain body. A portion of the second belt layer and/or a portion of thefirst belt layer may be directly attached to the outer cover layer.Alternatively, the front belt and rear belt 84, 86 may compriselongitudinally spaced webs of material forming a first surface of thebelt wherein the webs are folded along the waist edge, or alternativelythe leg opening edge, of the belt to wrap the elastomeric material andform at least a portion of the second surface of the belt. In otherwords, at least a portion of the inner surface and outer surface of eachof the belt portions may be formed from a single web of material.

In the embodiment shown in FIGS. 4C and 4D, the absorbent articles 20may comprise front and rear extensible belts 84, 86 disposed in thefront and rear waist regions 26, 28 respectively and intended toencircle at least a portion of the waist of the wearer, the front andrear belts 84, 86 being connected by the main body that forms the crotchregion 30 of the article. The first and second belt may be formed from afirst belt layer 82 (e.g., a “full outer cover nonwoven” or an “outercover web”) extending from a first waist edge 134 in a first waistregion 26 through the crotch region to a longitudinally opposing secondwaist edge 138 in a second waist region 28 and forming a portion of theouter surface of the absorbent article 20. The front and rear belts 84,86 also may comprise a second belt layer 83 a and b (e.g., an “innerbelt web”) forming a portion of the inner surface 24 of the absorbentarticle, the second belt layer may be formed of two longitudinallyspaced webs of material. The first and second belt portions may alsocomprise an elastomeric material 200 (e.g., “elastic elements” or“elastics”) disposed between the first and second belt layers. Theelastomeric material may comprise elastic strands, elastomeric films,elastomeric ribbons, elastomeric nonwovens, elastomeric filaments,elastomeric adhesives, elastomeric foams, scrims or combinationsthereof. The main body 38 (“central or center chassis”) of the absorbentarticle may comprise an outer surface 22, backsheet 60, an inner surface24, topsheet 58, and an absorbent core 62 disposed between the topsheet58 and the backsheet 60. The first belt layer may form a portion of theouter surface 22. In addition, the main body may comprise elasticizedbarrier leg cuffs 64 disposed at or adjacent the side edges of the mainbody. The second belt layer may overlap at least a portion of the mainbody and one or both of the second belt layer webs may form the outersurface of the first belt layer or alternatively the inner surface ofthe first belt layer. Alternatively, the front portion and/or the rearportion of the first belt layer 82 may be folded along the waist edge ofthe belt region to wrap the elastomeric material and form a portion ofthe second belt layer of one or both of the front and rear belt portions84, 86. In other words, the inner surface and outer surface of each ofthe belt portions may be formed from a single web of material. FIG. 6 isplan view of the embodiment consistent with FIG. 4D.

As can be seen in FIG. 6, the elastics 200 in the front and/or rearregions 26, 28 may extend into the crotch region 30 (that is, the firstplurality of elastics 216 and the second plurality of elastics 217 maybe disposed in the front and/or rear regions 26, 28, as well as thecrotch region). The front and crotch regions 26, 30 may be separated bya first axis 202 struck between a leg end edge 204 a of the first sideseam 32 a to a leg end edge 204 a of the second side seam 32 b, alongthe first belt layer 82, the first axis 202 defining the transitionbetween the front region 26 and the crotch region 30. Further, the rearand crotch regions 28, 30 may be separated by a second axis 206 struckbetween a leg end edge 204 c of the first side seam 32 a to a leg endedge 204 d of the second side seam 32 b, along the second belt layer 83,the second axis 206 defining the transition between the rear region 28and the crotch region 30. It should be understood that the seams areopened and the article is laid flat such that 32 a-d indicate where theseam is formed when the front and back belts are joined together.

FIG. 6 also illustrates that a majority of the elastics 200 may notoverlap the center chassis 38. It may be desirable that none of theelastics 200 overlap the center chassis 38. In the embodimentillustrated in FIG. 6, only one or two overlap the end edges of thecenter chassis 38. It may also be desirable to overlap a portion of thecenter chassis 38, excluding the absorbent core 62.

One way to keep elastics from overlapping the absorbent core is to severan unglued area of the elastics prior to placing the absorbent core ontothe belts. The elastics can then snap back to a section of gluedelastics (e.g., 210).

In the embodiment shown in FIG. 4E and 4F, the absorbent articles 20 maycomprise a full outer cover layer 42, extending from a front waist edge134 in a first waist region 26, through the crotch region to thelongitudinally opposing rear waist edge 138 in a second waist region 28.The article may also comprise front and rear belts 84, 86 intended toencircle the waist of the wearer, the front and rear belts 84, 86 beingconnected to the outer cover layer 42 and/or the main body 38 of theabsorbent article 20. The first and second belts are formed from a firstbelt layer forming a portion of the outer surface of the belt, the firstbelt layer being formed of two longitudinally spaced webs of material.The first and second belt portions also comprise a second belt layerforming a portion of the inner surface of the absorbent article, thesecond belt layer also being formed of two longitudinally spaced webs ofmaterial. The first and second belt layers may be formed ofsubstantially the same material or may comprise different materials. Thefirst and second belt layers may be formed from nonwovens, films, foamsor combinations thereof. The first and second belts may also comprise anelastomeric material disposed between the first and second belt layers.The elastomeric material may comprise elastic strands, elastomericfilms, elastomeric ribbons, elastomeric nonwovens, elastomericfilaments, elastomeric adhesives, elastomeric foams, scrims orcombinations thereof. The first and second belts may be disposed on theinterior surface of the outer cover layer. Alternatively, the first andsecond belts may be disposed on the outer surface of the outer coverlayer. In such an embodiment the outer cover layer would for a portionof the inner surface of the article in the waist regions and the firstbelt layer would form a portion of the outer surface of the article. Thesecond belt layer when present may be disposed between the first beltlayer and the outer cover layer. The main body 38 of the absorbentarticle 20 may comprise an outer surface 22, backsheet 60, an innersurface 24, topsheet 58, and an absorbent core 62 disposed between thetopsheet 58 and the backsheet 60. In addition, the main body 38 maycomprise elasticized barrier leg cuffs 64 disposed at or adjacent theside edges of the main body 38. One or both of the front and rear belts84, 86 may overlap at least a portion of the main body 38 and one orboth of the belts may be disposed on the outer surface of the main body38 or alternatively on the inner surface of the main body 38. One orboth of the front and rear belts 84, 86 may be disposed on the interiorsurface of the outer cover layer or alternatively one or both of thebelts may be disposed on the exterior surface of the outer cover layer.One or both of the front belt and rear belt 84, 86 may compriselongitudinally spaced webs of material forming a first surface of thebelt wherein the webs are folded along the waist edge 36 of the belt towrap the elastomeric material and form at least a portion of the secondsurface of the belt. In other words, a portion or the entirety of theinner surface and outer surface of one or both of the belt portions maybe formed from a single web of material. The rugosities, wrinkles, foldsin one or both of the front and rear belts may have a differentconfiguration, size, orientation, shape, etc. than that of the outercover layer.

In the embodiment shown in FIG. 4G, the absorbent articles 20 maycomprise front and rear belts 84, 86 intended to encircle at least aportion of the waist of the wearer, the front and rear belts 84, 86being connected to a main body 38 forming a portion of the crotch region30 of the absorbent article 20. The front and rear belts 84, 86 areformed from a first belt layer 82 forming a portion of the outer surfaceof the absorbent article. The front and rear belt portions 84, 86 alsocomprise a second belt layer 83 forming a portion of the inner surface24 of the absorbent article 20. The second belt layer may be laterallydiscontinuous and spaced apart in a transverse direction. The first andsecond belt layers 82, 83 may be formed of substantially the samematerial or may comprise different materials. The first and second beltlayers 82, 83 may be formed from nonwovens, films, foams or combinationsthereof. The front and rear belt portions 84, 86 may also comprise anelastomeric material disposed between the first and second belt layers82, 83. The elastomeric material may comprise elastic strands,elastomeric films, elastomeric ribbons, elastomeric nonwovens,elastomeric filaments, elastomeric adhesives, elastomeric foams, scrimsor combinations thereof. A portion of the elastomeric material may bedirectly combined with the outer cover layer. The main body 38 of theabsorbent article may comprise an outer surface 22, backsheet 60, aninner surface 24, topsheet 58, and an absorbent core 62 disposed betweenthe topsheet 58 and the backsheet 60. In certain embodiments thebacksheet may be a nonwoven and film laminate wherein the nonwoven isformed by the outer cover layer. In addition, the main body 38 maycomprise elasticized barrier leg cuffs 64 disposed at or adjacent theside edges of the main body 38. The front and rear belts 84, 86 overlapat least a portion of the main body 38 and one or both of the belts maybe disposed on the outer surface of the main body 38. A portion of thesecond belt layer and/or a portion of the first belt layer may bedirectly attached to the outer cover layer. The front and rear belts 84,86 may be formed from a first belt layer extending from a first waistedge 134 in a first waist region 26 through the crotch region to asecond waist edge 138 in a second waist region 28 and forming a portionof the outer surface of the absorbent article 20. The front and rearbelts 84, 86 may also comprise a second belt layer extending from afirst waist edge 134 in a first waist region 26 through the crotchregion to a second waist edge 138 in a second waist region 28 andforming a portion of the inner surface of the absorbent article 20. Thefirst and second belt layers may be formed of substantially the samematerial or may comprise different materials. The first and second beltlayers may be formed from nonwovens, films, foams, woven materials orcombinations thereof. The front and rear belt portions 84, 86 may alsocomprise an elastomeric material disposed between the first and secondbelt layers in one or both of the first and second waist regions 26, 28.The elastomeric material may comprise elastic strands, elastomericfilms, elastomeric ribbons, elastomeric nonwovens, elastomericfilaments, elastomeric adhesives, elastomeric foams, scrims orcombinations thereof. The main body 38 of the absorbent article 20 maycomprise an outer surface 22, backsheet 60, an inner surface 24,topsheet 58, and an absorbent core 62 disposed between the topsheet 58and the backsheet 60. One or both of the first and second belt layersmay form a portion of the outer surface 22. In addition, the main body38 may comprise elasticized barrier leg cuffs 64 disposed at or adjacentthe side edges of the main body 38. A portion of one or both of thefront and rear belts 84, 86 may overlap at least a portion of the mainbody 38. Alternatively, the front belt portion and rear belts 84, 86 maycomprise a belt layer forming a first surface of the belt portionwherein the belt layer may be folded along the waist edge of the beltportion to wrap the elastomeric material and overlap a portion of theopposing belt layer. In other words, a portion of the inner surface anda portion of the outer surface of each of the belt portions may beformed from a single web of material.

A portion or the whole of the main body 38 may be made extensible to adegree greater than the inherent extensibility of the material ormaterials from which the main body 38 is made, e.g., the backsheet 60.The additional extensibility may be desirable in order to allow the mainbody 38 to conform to the body of a wearer during movement by the wearerand or to provide adequate body coverage. The additional extensibilitymay also be desirable, for example, in order to allow the user of aabsorbent article including a main body 38 having a particular sizebefore extension to extend the front waist region 26, the back waistregion 28, or both waist regions of the main body 38 to provideadditional body coverage for wearers of differing size, i.e., to tailorthe article to the individual wearer. Such extension of the waist regionor regions may give the main body 38 a generally hourglass shape, solong as the crotch region is extended to a relatively lesser degree thanthe waist region or regions, and may impart a tailored appearance to thearticle when it is worn. In addition, the additional extensibility maybe desirable in order to minimize the cost of the article 10. Forexample, an amount of material that would otherwise be sufficient onlyto make a relatively smaller article lacking this extensibility can beused to make an article capable of being extended to adequately cover awearer that is larger than the unextended smaller absorbent articlewould fit.

A portion of the main body 38, for example a portion of the chassis inone or both of the waist regions 26, 28 may be made laterally extensibleto a maximum extensibility greater than a maximum extensibility ofanother portion of the main body 38 in the crotch region such that alateral extension of each of the portions to its maximum extensibilityimparts an hourglass shape to the main body 38. In one embodiment, theportion of the main body 38 underlying and/or immediately adjacent oneor both of the front and back extensible belts may be made laterallyextensible to a maximum extensibility greater than a maximumextensibility of another portion of the main body 38, for example thecrotch region, such that a lateral extension of each of the portions toits maximum extensibility facilitates application of the absorbentarticle onto the body of a wearer by enabling the waist regions to beextended to fit over the wearer's hips and in addition, opening andorienting the leg openings enabling the wearer to place the legs throughthe openings more effectively.

Additional lateral extensibility in the main body 38 may be provided ina variety of ways. For example, a material or materials from which themain body 38 is made may be pleated by any of many known methods.Alternatively, all or a portion of the main body 38 may be made of aformed web material or a formed laminate of web materials like thosedescribed in U.S. Pat. No. 5,518,801 issued on 21 May 1996 in the nameof Chappell et al. This formed web material includes distinct laterallyextending regions in which the original material has been altered byembossing or another method of deformation to create a pattern ofgenerally longitudinally oriented alternating ridges and valleys andalso includes laterally extending unaltered regions between thelaterally extending altered regions. The formed web material can beextended in a direction perpendicular to the ridges up to the pointwhere the ridges and valleys flatten with substantially less force thanis required to extend beyond that point. In addition to lateralextensibility, the creation of a formed laminate web as described aboveprovides a main body 38 backsheet with improved texture and cloth-likeappearance and feel. The deformation creates a cloth-like pattern in thefilm and increases the loft of the nonwoven in multi-layer film andnonwoven laminate backsheets.

Alternatively, a portion of the absorbent article can be ring-rolled andthus rendered highly extensible as described in U.S. Pat. No. 5,366,782(issued Nov. 22, 1994 to Curro, et al). Specifically, a ring-rollingapparatus includes opposing rolls having intermeshing teeth thatincrementally stretch and thereby plastically deform the materialforming the absorbent article (or a portion thereof) thereby renderingthe article extensible in the ring-rolled regions. In one embodiment,the absorbent article can be ring-rolled in a portion of at least one ofthe front or back waist regions, for example the portion of the mainbody 38 underlying and/or immediately adjacent one or both of the frontand back belts 84, 86, while other regions may comprise a structuredelastic-like formed web material. The article may be ring-rolled acrossthe entire width in one or both of the waist regions or alternativelymay be ring-rolled over only a portion of the main body 38 width or overonly a portion of one or both of the belts.

The front laterally central portion and the back laterally centralportion of the main body 38 may have a different range of extensibilityfrom other portions of the main body 38.

Additionally or alternatively, the laterally central portions may beextensible to a greater or lesser degree when subjected to a given levelof opposing tensile forces, i.e., may be more easily or less easilyextensible, than other portions of the main body 38.

The main body 38 may comprise a liquid pervious topsheet 58, a liquidimpervious backsheet 60 and an absorbent core 62 disposed therebetween.The main body 38 may additionally comprise a barrier leg cuff 64disposed along the longitudinal side edge 48. The barrier leg cuff 64provides improved containment of liquids and other body exudates in thecrotch region 30. The barrier leg cuff 64 shown in FIG. 5 comprises asingle layer of material which may be folded to form a barrier leg cuffhaving two layers. The barrier leg cuff 64 extends from the side of themain body at or adjacent the longitudinal side edge 48 toward thelongitudinal centerline L2. The barrier leg cuff may be folded along thefolding line 66 back toward the longitudinal side edge 48. The barrierleg cuff 64 may have a first barrier cuff elastic material 72 adjacentto the distal portion 68 and a second barrier cuff elastic material 73adjacent to the proximal portion 70 of the barrier leg cuff 64. Theproximal portion 70 of the barrier leg cuff 64 may be joined to thebacksheet 60 adjacent to the longitudinal side edge 48. The portion ofthe barrier leg cuff 64 along the folding line 66 and the distal portion68 may be free from attachment to any portion of the main body 38 in thecrotch region 30 such that the barrier leg cuff 64 stands up toward thewearer's body. The transverse end 74 of the barrier leg cuff 64 may bejoined to the topsheet 58 at or adjacent the longitudinally opposingends of the leg cuff by an attachment means which may be any known meanssuch as an adhesive, heat bond, pressure bond or the like as shown inFIG. 5A. Examples of acceptable cuffs 64 are disclosed in U.S. Ser. No.13/457,521, filed Apr. 27, 2012, including the configurations disclosedby FIGS. 8a -t. For, instance, as illustrated in FIG. 5B, the barrierleg cuff may be a two-piece cuff And, the cuff 64 may be joined to thebacksheet with a no leak bead 215 that runs along the entirelongitudinal length of the cuff and/or the backsheet film 60.

The liquid pervious topsheet 58 may be positioned adjacent thebody-facing surface of the absorbent core 62 and may be joined theretoand/or to the backsheet 60 by any attachment means known in the art. Theliquid impervious backsheet 60 is generally that portion of theabsorbent article 20 positioned adjacent the garment-facing surface ofthe absorbent core 62 and prevents the exudates absorbed and containedtherein from soiling articles that may contact the absorbent article 20.The absorbent core is positioned between the topsheet 58 and thebacksheet 60 and absorbs and retains liquids such as urine and othercertain body exudates.

The topsheet 58, the backsheet 60 and the absorbent core may bemanufactured any known materials. Suitable topsheet materials mayinclude porous foams; reticulated foams; apertured plastic films; orwoven or nonwoven webs of natural fibers (e.g., wood or cotton fibers),synthetic fibers (e.g., polyester or polypropylene fibers), or acombination of natural and synthetic fibers. Suitable backsheetmaterials may include breathable materials that permit vapors to escapefrom the diaper while still preventing exudates from passing through thebacksheet.

A suitable absorbent core for use in the absorbent article 20 maycomprise any absorbent material which is generally compressible,conformable, non-irritating to the wearer's skin, and capable ofabsorbing and retaining liquids such as urine and other certain bodyexudates. In addition, the configuration and construction of theabsorbent core may also be varied (e.g., the absorbent core(s) or otherabsorbent structure(s) may have varying caliper zones, hydrophilicgradient(s), a superabsorbent gradient(s), or lower average density andlower average basis weight acquisition zones; or may comprise one ormore layers or structures). In some embodiments, the absorbent core maycomprise a fluid acquisition component, a fluid distribution component,and a fluid storage component. An example of a suitable absorbent corehaving a fluid acquisition component, a fluid distribution component,and a fluid storage component is described in U.S. Pat. No. 6,590,136.Examples of acceptable air felt free cores (i.e., absorbent core systemshaving little or no air felt) are disclosed in U.S. Pat. Nos. 5,562,646,7,750,203, 7,744,576 and U.S. Pub. Nos. 2008/0312617A1, 2008/0312619A1,and 2004/0097895A1.

The outer cover layer 42 may be disposed on the outer surface 22 of theabsorbent article 20 and covers the crotch panel 56 of the absorbentmain body 38. The outer cover layer 42 may extend into and cover thefront waist panel 52 and the back waist panel 54 of the main body 38.The outer cover layer may form a portion of the backsheet and/or themain body. The outer cover layer 42 may be directly joined to and covera portion or all of the liquid impervious backsheet 60 of the main body38. The central panel 80 of the front and back belt 84, 86 may be joinedto the front waist panel 52 and the back waist panel 54 of the main body38 through the outer cover layer 42. Thus, the outer cover layer 42 isdisposed between the front and back belt 84, 86 and the liquidimpervious backsheet 60 of the main body 38. In one embodiment shown inFIGS. 2 and 4C, the outer cover layer 42 is coextensive with the liquidimpervious backsheet 60. The leg elastic material 140 is disposed so asto extend generally longitudinally along the longitudinal side edge 48of the main body 38. The leg elastic material 140 may be disposed atleast in the crotch region 30 of the absorbent article 20 or may bedisposed along the entirety of the longitudinal side edge 48.

The outer cover layer 42 may comprise a material separate from thematerial of the inner layer 83 and the outer layer 82 constituting thebelt 40. The outer cover layer 42 may comprise two or more layers ofmaterials. The outer cover layer 42 may comprise any known materials andmay comprise materials used for the front and back belt 84, 86 asexplained above. The outer cover layer 42 may comprise a single layer ofnonwoven web of synthetic fibers. The outer cover layer 42 may comprisea single layer of hydrophobic, non-stretchable nonwoven material. Theouter cover layer may comprise a film, a foam, a nonwoven, a wovenmaterial or the like and/or combinations thereof such as a laminate of afilm and a nonwoven.

The belt 40 may comprise a front belt 84 and a back belt 86 (hereinaftermay be referred to as “front and back belt 84, 86) and has a ring-likeconfiguration by permanently or refastenably connecting the front belt84 and the back belt 86 at the seams 32 or by permanently orrefastenably connecting the front and/or back belt to the main body 38.Articles of the present disclosure may have refastenable elements,configurations, and methods of making as disclosed in U.S. Ser. No.61/787,416, filed on Mar. 15, 2013, as well as U.S. Ser. No. 61/787,332,filed on Mar. 15, 2013.

The belt 40 may be ring-like and elastic. The ring-like elastic belt 40extends transversely about the waist opening 36 of the absorbent article20 and acts to dynamically create fitment forces and to distribute theforces dynamically generated during wear. Applicants have found thatimproved fit can be created by controlling the distance between, lineardensity, and and the pre-strain of the elastomeric material in relationto each other and to the openings for the body. This may occur bychoosing different materials throughout the belt 40 that exhibit desiredproperties. The different materials are combined at specific distances,linear densities, and prestrains to create a belt 40 that acts todynamically create fitment forces. Particularly, the articles of thisdisclosure may have the characteristics of the articles of Examples 1-4as disclosed in U.S. Ser. No. 13/764,990, filed Feb. 12, 2013. Articlesof the present disclosure may also have the same stress, strain andspacing of its elastics as disclosed in U.S. Ser. No. 13/764,990 and/oras disclosed in U.S. Ser. No. 61/598,012, filed Feb. 13, 2012. Articlesof the present disclosure may also have the same elastic sections andforce zones disclosed in U.S. Ser. No. 13/764,990.

The front belt 84 may comprise 5 to 50 elastic strands. The front belt84 may comprise 10 to 20 elastic strands. The back belt 86 may comprise5 to 50 elastic strands. The back belt 86 may comprise 10 to 20 elasticstrands. The elastic strands are distributed amongst the different forcezones. Elastic strands may be distributed evenly amongst the forcezones. Elastic strands may also be distributed unevenly amongst thedifferent force zones. Each force zone comprises at least one elasticstrand.

The elastic strands may have a linear density between 200 to 2500.Linear density is the density of the elastic fibers in the elasticstrand. The most commonly used unit for the linear density is thedecitex, abbreviated dtex, which is the mass in grams per 10,000 meters.The linear density may be used to change the force profile. For example,one could reach a desired force profile by selecting the linear densityof a single elastic strand, combining multiple elastic strands with asmaller linear density in close proximity to each other, and/orcombining with other elastomeric materials.

The elastic strands may have an elastic pre-strain. The elasticpre-strain is the percent of length increase in an elastic strand orplurality of elastic strands at the point of combining the elastic(s)with the first and/or second belt layers. For example a strand with afree length of 15 centimeters (cm) may have a load applied such that the15 cm elastic strand is now 18 cm long. This length increase of 3 cm is20% of 15 cm (3/15), or a 20% strain. The elastic pre-strain may be usedto change the force profile of a single elastic strand or a plurality ofelastic strands. Force profiles may also be changed by changing thelinear density in conjunction with the elastic pre-strain of one or moreelastic strands.

The number of elastic strands in each zone may be changed according tothe placement of the absorbent core. Applicants have found that the useof thinner absorbent cores may lead to a need in increased elastic forceto compensate for the change in article thickness. The force profilemust be adjusted depending on the location and thickness of theabsorbent core. This particularly affects the second elastic section andthird elastic section.

The elastic strands disposed in the belt may be aligned in a curvedfashion so that the a tangent of the curve of the elastic strands mayform an acute angle with the centerline or may form an arcuate shape.This may allow for targeting the force profile and/or coordinating printand elastication/rugosities/elastics in the stretch sections.

It may be desirable to use the hot air seaming processes, as well as thearticle forming processes disclosed in U.S. Pat. No. 6,248,195 and U.S.Ser. Nos. 12/795,021, 13/401,907, and 13/402,056 for seaming articles asdisclosed herein. And, the articles disclosed herein may have graphicsin accordance with U.S. Ser. Nos. 61/646,953 and 61/646,979, each filedon May 15, 2012.

TEST METHODS SECTION

Test Equipment/Environment

A suitable tensile tester such as an MTS Alliance with MTS Testworksversion 4.0 or equivalent instrument is used. The tester is equippedwith flat clamps that are capable of holding at least the entiretransverse length of the side seam should be used. The instrument iscalibrated according to the manufacturer's specification. Testing isperformed at 23° C.±2° C. and 50%±2% relative humidity.

Sample Prep

The side seams of the product are broken to separate the front belt fromthe back belt. The respective force zones (as described in the DetailedDescription of the Invention) are cut away from these belts. Eachseparated section of the front and back belt will be referred to as a“test sample” herein. All material layers, including the chassiscomponents, should be kept with the test sample. All cut lines arestraight, parallel to the transverse direction of the absorbent article.Each test sample needs to have at least one elastomeric material. Thewidths (a dimension in the longitudinal direction of the absorbentarticle) of the respective zones are measured.

The length of the test sample is determined. The length measures in thetransverse direction of the absorbent article a distance from one end tothe other end of a test sample in a fully stretched condition. The fullystretched condition is the condition where the test sample is stretchedby the force of 0.1 N/mm multiplied by the width of the test sample. Ifone or both ends of a test sample are not parallel to the longitudinaldirection, the shortest length within the test sample is considered asthe length of the test sample.

An adjusted test sample length is defined such that the length of a testsample minus the combined length of any material in the upper and lowerclamps. Thus, if a test sample is mounted in the clamp so that 10 mm ateach end is held in the clamps, then the adjusted belt length is themeasured belt length minus 20 mm.

The test samples are kept unstretched at least for 10 min before thetest.

Test

For each test sample, the initial gauge length of the tensile tester isset to allow the test sample to be mounted in a relaxed state. The loadcell is zeroed to offset the sample weight.

The test sample is stretched in the transverse direction of theabsorbent article at a rate of 254 mm/min, and a load (N) is measuredwithin 5 sec after the test sample reaches at 65% of the adjusted testsample length. The transverse force is calculated for each of the forcezones according to an equation:A transverse force (N/mm) of a test sample=Measured value (N)/width ofthe force zone (mm)

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numeral values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this written document conflicts with any meaningor definition of the term in a document incorporated by reference, themeaning or definition assigned to the term in this written documentshall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An absorbent article comprising a front region, acrotch region, and a back region, the absorbent article comprising: afirst inner belt web; a first outer belt web; wherein the first innerand outer belt webs are joined to form a first belt; a second inner beltweb; a second outer belt web; wherein the second inner and outer beltwebs are joined to form a second belt; a first plurality of elasticsdisposed between the first inner belt web and the first outer belt web;a second plurality of elastics disposed between the second inner beltweb and the second outer belt web; a center chassis having a first endand a second end, the center chassis comprising a topsheet and abacksheet and a core therebetween, the backsheet comprising a film and anonwoven, the backsheet being shaped at side edges to form atransversely narrow portion of the backsheet at the crotch region versustransversely wide portions adjacent to and at the front and backregions; wherein the first belt is joined to a garment-facing side ofthe center chassis adjacent to the first end and the second belt isjoined to the garment-facing side of the center chassis adjacent to thesecond end; wherein the first belt overlaps the first end and is joinedto a wearer-facing surface of the center chassis; wherein the secondbelt overlaps the second end and is joined to the wearer-facing surfaceof the center chassis; wherein the first and second belts are joined toform a waist opening and two leg openings; wherein the center chassiscomprises leg cuffs and wherein a center portion of the leg cuffsdisposed in at least a portion of the crotch region extend laterallyoutboard of a side edge of the backsheet; and wherein at least a portionof the leg cuffs are joined to a wearer-facing surface of the topsheetand a wearer-facing surface of the backsheet film.
 2. The absorbentarticle according to claim 1, wherein the first plurality of elasticsare disposed in the front and crotch regions.
 3. The absorbent articleaccording to claim 1, wherein the second plurality of elastics aredisposed in the back and crotch regions.
 4. The absorbent articleaccording to claim 1, wherein the portions of the first belt making upthe leg openings has a concave portion.
 5. The absorbent articleaccording to claim 1, wherein the portions of the first belt making upthe leg openings has a convex portion.
 6. The absorbent articleaccording to claim 1, wherein the portions of the second belt making upthe leg openings has a concave portion.
 7. The absorbent articleaccording to claim 1, wherein the portions of the second belt making upthe leg openings has a convex portion.
 8. The absorbent articleaccording to claim 1, wherein the center chassis has non-linear sideportions.
 9. The absorbent article according to claim 1, wherein thefirst and second belts do not comprise curved elastics.
 10. Theabsorbent article according to claim 1, wherein the first and secondplurality of elastics are parallel to each other and transverse to alongitudinal centerline of the article.
 11. The absorbent articleaccording to claim 2, wherein the first plurality of elastics arevarying transversely extending widths in the crotch region.
 12. Theabsorbent article according to claim 3, wherein the second plurality ofelastics are varying transversely extending widths in the crotch region.13. The absorbent article according to claim 1, wherein at least aportion of the first plurality of elastics and/or at least a portion ofthe second plurality of elastics overlaps at least a portion of thecore.
 14. The absorbent article according to claim 1, wherein a sideedge of the leg cuff extends laterally outboard of a side edge of thetopsheet.
 15. The absorbent article according to claim 1, wherein thecenter portion of the leg cuff along a transverse axis of the chassisextends laterally outboard of the side edge of the backsheet.
 16. Theabsorbent article according to claim 1, wherein a side edge of the legcuff extends laterally outboard of a side edge of the topsheet and theside edge of the backsheet in at least the crotch region.
 17. Theabsorbent article according to claim 1, wherein end portions of the legcuffs disposed in at least a portion of the front and back regions arelaterally inboard of the side edge the backsheet.
 18. The absorbentarticle according to claim 1, wherein the first outer belt web and thesecond outer belt web are formed by a continuous nonwoven layer.
 19. Theabsorbent article according to claim 1, wherein the first plurality ofelastics are disposed in the front waist region and the crotch region.20. The absorbent article according to claim 19, wherein the secondplurality of elastics are disposed in the back waist region and thecrotch region.